Handheld computing device

ABSTRACT

A handheld computing device is disclosed. The handheld computing device includes a seamless housing formed from an extruded metal tube. The extruded tube includes open ends and internal rails which serve as a guide for slidably assembling an operational assembly through the open ends of the extruded tube, a reference surface for positioning the operational assembly relative to an access opening in the seamless housing, and a support structure for supporting the operational assembly during use.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. application Ser. No.13/766,312, filed Feb. 13, 2013, entitled “HANDHELD COMPUTING DEVICE”,which a continuation of U.S. application Ser. No. 12/551,384, filed Aug.31, 2009, now U.S. Pat. No. 8,385,060, entitled “HANDHELD COMPUTINGDEVICE”, the contents of which are incorporated herein by reference intheir entirety for all purposes.

FIELD

The present invention relates generally to portable computing devices.More particularly, the present invention relates to enclosures ofportable computing devices and methods of assembling portable computingdevices.

BACKGROUND

In recent years, portable computing devices such as laptops, PDAs, mediaplayers, cellular phones, etc., have become small, light and powerful.One factor contributing to this reduction in size can be attributed tothe manufacturer's ability to fabricate various components of thesedevices in smaller and smaller sizes while in most cases increasing thepower and or operating speed of such components. Unfortunately, thetrend of smaller, lighter and powerful presents a continuing designchallenge in the design of some components of the portable computingdevices.

Conventional assembly techniques teach placing the operationalcomponents within the enclosure sections at a time after which they areelectrically connected. However, even though the individual componentcan be pre-tested prior to assembly, there is no way to pre-test theassembled components. The only testing that can occur takes place eitherduring the assembly process or immediately after the assembly process iscomplete. If there is a fault discovered, or the device fails to meetoutgoing functional quality requirements, the entire device is eitherscrapped or dis-assembled in order to find and correct the defectivecomponent thereby greatly reducing efficiency and increasing costs.

In view of the foregoing, there is a need for improved component densityand associated assembly techniques that reduce cost and improve outgoingquality. In addition, there is a need for improvements in the manner inwhich small, handheld devices are assembled. For example, improvementsthat enable structures to be quickly and easily installed within theenclosure, and that help position and support the structures in theenclosure. It is also desirable to minimizing the Z height of theassembled components in order to reduce the overall thickness of theportable computing device and thereby improve the overall aesthetic lookand feel of the product.

SUMMARY

A portable electronic device is disclosed. The portable electronicdevice includes at least a frame and a device module mounted to theframe. The device module includes a first function assembly, a secondfunction assembly, and an electrical interface configured to facilitatecommunication between the first and the second function assemblies. Thefirst and the second function assemblies are movable relative to oneanother. The electrical interface can expand or contract commensuratewith the relative displacement between the first and the secondassemblies. The portable electronic device also includes a userinterface module electrically coupled to the device module. The devicemodule and the user interface module are each stand alone modules inthat each can be fully function tested prior to being incorporated intothe portable electronic device.

A method of assembling a portable electronic device is disclosed. Themethod can be carried out by performing at least the followingoperations. Providing a seamless housing, the seamless housing having atleast a first open end and a reference structure formed on an insidesurface of the housing, inserting a pre-tested device module into thefirst open end using a resilient reference structure as a guide. Thedevice module includes a first function assembly and a second functionassembly the first function assembly being fixed to the frame and thesecond function assembly being moveably mounted to the frame such thatthe second function assembly can move relative to the first functionassembly. Next, affixing the location of the first function assembly toan reference point on the seamless housing and moving the secondfunction assembly in relation to the fixed first function assembly.

A user interface module for use in a portable electronic device isdisclosed. the user interface module including at least a user touchinterface having a plurality of discrete regions sensitive to a user'stouch, a plurality of actuators each being responsive to a user touchevent at a corresponding one of the plurality of touch sensitiveregions, a flexible electrical connector configured to electricallyconnect the plurality of actuators to a connector, and a diffusionbonded support plate formed of a number of chemically etched layers, thesupport place providing support to the user interface assembly, whereinthe user interface module is fully pre-tested prior to installation inthe portable electronic device.

An integrated connector adapted for electrically connecting each of aplurality of components to an external circuit independent of oneanother where the components arranged in at least two dimensions isdisclosed. The integrated flex connector including at least a singleelectrical board to board connector, a first portion having a firstconnector electrically connected to the single electrical board to boardconnector, a second portion independent of the first portion, the secondportion having a second connector electrically connected to the singleelectrical board to board connector, and a third portion independent ofthe first portion and the second portion, the third portion having athird connector electrically connected to the single electricalconnector, wherein the single electrical connector provides anindependent electrical path for the each of the first, second, and thirdconnectors to the external circuit.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention will be readily understood by the following detaileddescription in conjunction with the accompanying drawings, wherein likereference numerals designate like structural elements, and in which:

FIG. 1A shows a generic block diagram a modular portable electronicdevice in accordance with the described embodiments.

FIG. 1B is a perspective diagram of an embodiment of a handheldcomputing device.

FIG. 2 shows an exploded view of portable electronic device shown inFIG. 1 illustrating the juxtaposition of various electrical andstructural components described in more detail below.

FIG. 3 is a perspective diagram of an embodiment of seamless housingused to form the handheld computing device shown in FIG. 1.

FIG. 4 shows various views of click wheel assembly. The views include anexploded view and a reverse view of click wheel flex showing reversedome buttons in accordance with the described embodiments.

FIG. 5 shows a front and rear view of m-frame assembly in accordancewith the described embodiments.

FIG. 6 shows an embodiment of metal frame used in the fabrication ofm-frame assembly of FIG. 5.

FIG. 7 shows an embodiment of display device showing a cross over flexin a folded state and an extended, or open, state.

FIGS. 8A-8C shows an embodiment of camera module and camera boot.

FIG. 9 shows an embodiment of I/O flex.

FIG. 10 shows a top and bottom view of audio module in accordance withthe described embodiments.

FIG. 11 shows a representation of cover glass assembly and displaydevice in relation to metal frame in accordance with the describedembodiments.

FIGS. 12-14 shows a flowchart detailing a process for manufacturing aportable electronic device in accordance with the embodiments describedherein.

DETAILED DESCRIPTION

The invention generally pertains to portable computing devices and moreparticularly to components of and methods for assembling portablecomputing devices. One aspect of the invention relates to a seamlesshousing formed of a material such as plastic or metal such as aluminum.The seamless housing can be formed via an extrusion process. Themetallic nature of the seamless housing can provide superior wearproperties as well as provide superior impact protection for internalcomponents in addition to provide an electrical grounding plane. Inaddition to providing superior wear and protection, the metal used toform the seamless housing can be worked to provide a more aestheticallypleasing appearance thereby improving the overall user experience. Forexample, the sheen and luster of aluminum can be used to provide anaesthetically pleasing appearance to the portable computing device.

The seamless housing can also include at least one open end, a window toreceive a display device, and an opening to receive a user input device,such as a touch sensitive click wheel. The open end can be sized forslideably receiving a m-frame assembly, also referred to as a sled,formed of a number of operational components mounted to a metal frame.The metal frame can be used as a metal support on which a number ofoperational components can be mounted at a fixed position on the metalframe. Other components, however, can be mounted on the metal frame andyet still be moved relative to the fixed components. In this way, anassembly operator can easily align those components that must be placedin specific locations (such as the audio jack and connector being flushto the bottom of the housing) while the other components remain fixed.The operational components mounted to a fixed position on the metalframe can include a display device since it is critical that the displaydevice remain centered in the display window. Components that can bemounted and yet still be moved in relation to the display device caninclude a main logic board also referred to as a printed circuit board(PCB). The PCB can act as a transport vehicle for components attachedthereto such as a microprocessor, a microphone, a camera, a data porthaving a connector, a piezo-electric audio transducer, and an audiojack. In the case of the audio jack, the ability to move the PCB inrelation to the display enables an assembly operator to move the audiojack flush to the bottom of the portable electronic device while stillmaintain the proper centering of the display.

In order to increase density of components mounted to the metal frame,the number of board to board interconnects, the pitch betweeninterconnects, and the amount of board real estate used forinterconnects can be optimized. This optimization can be carried out ina number of ways. For example, using surface mount and solderingwhenever possible provides for reduced use of board real estate andbetter electrical connections than would otherwise be used if aconventional connector was used. An integrated flex where a number ofcomponents are soldered to a single flex structure having a single boardto board connector is one approach that takes advantage of both surfacemount, soldering, and reduced number of connectors. A stiffener platecan be used to disperse stress on the flex at a connection. Thestiffener plate can be metal and also used to provide a groundconnection.

The single integrated flex can be used to connect a plurality ofdifferent operational components. The single integrated flex can includea single board to board interconnect suitable for providing anelectrical connection between the plurality of operational componentsand a substrate or printed circuit board (PCB). The plurality ofoperational components connected by way of the single integrated flexcan include the audio jack and associated circuitry, the microphone, ahold switch, and the piezo-electric audio transducer. The singlyintegrated flex allows for pre-assembly testing of the componentsattached thereto simply by connecting the single board to boardconnector to a test fixture.

Another approach that can taken to facilitate assembly and therebyimprove assembly throughput is by providing novel techniques formounting components onto the metal frame. One such technique is referredto as “book” mounting whereby the metal frame is structured toaccommodate the placement of a component on one side of the metal frame.The assembly operator can then lower the component as if closing a bookonto the other side of the metal frame where a snap attachment featurecan be used to secure the component. Using this technique, the assemblyof small components onto the metal frame is easy and less time consumingthan conventional approaches to mounting components.

Typically, the m-frame assembly is formed in a pre-insertion assemblyoperation separate from the assembly process that is used to manufacturethe portable computing device. One of the advantages of pre-assemblingthe m-frame assembly is that once assembled, the m-frame assembly can befunctionally tested prior to being inserted into the housing. In thisway, only those m-frame assemblies that have been determined to passfunctional testing are used in the manufacture of the portable computingdevice thereby greatly improving assembly outgoing quality. Moreover, bybeing able to pre-test the m-frame assembly, any debugging, tuning, orrepair can be performed prior to the actual insertion of the m-frameassembly into the seamless housing.

In addition to the stand alone m-frame assembly, a stand alone touchsensitive user input device, such as a click or touch wheel, can beassembled and tested separately from the m-frame assembly. Similar tothe m-frame assembly, the stand alone user input device can befunctionally tested prior to assembly into the portable computingdevice. In this way an inventory of pre-tested stand alone m-framesubassemblies and stand alone click wheel assemblies can be created andcalled upon as needed in, for example, a just in time (JIT) typeassembly operation. Furthermore, the modularity of the stand alonem-frame assembly and click wheel assembly affords the opportunity toeasily repair a defective portable computing device by merely replacingthe defective click wheel assembly or m-frame assembly without the needto debug and repair in situ as is conventionally the case.

The click wheel assembly can include a number of components such as aclick wheel faceplate having a number of button function icons and acenter button. A number of dome buttons corresponding to the buttonfunction icons are connected to a flex structure separate from a flexstructure on which dome button corresponding to the center button ismounted. In the described embodiment, in order to reduce Z height, thedome buttons are mounted in a reverse orientation. Furthermore, bymounting the dome button associated with the center button on a separateflex structure than that used for the dome buttons corresponding to thecenter button, less material can be used. Additionally, all of thereverse mounted dome buttons are mounted to the same side of theirrespective flex structures. In this way, the dome button/flex structurescan be fabricated in a single set up.

Once the m-frame assembly has been properly inserted and the displaycentered and locked in place, the stand alone click wheel assembly canbe electrically connected and placed within the click wheel opening inthe housing. The click wheel assembly can grounded to a chassis ground(i.e., metal housing) by way of a metallic coil spring included in ahole formed in a click wheel support structure. The metallic spring canprovide both a path to ground (i.e., the metallic housing) and resilientsupport for the click wheel assembly.

A resilient reference structure on an interior surface of the seamlesshousing can be used as a guide during assembly. The resilient nature ofthe reference structure can be provided by resilient material, such asplastic, attached to a bottom surface of the seamless housing. Duringassembly, the m-frame assembly can be placed within the open end of theseamless housing. A display device chassis (usually formed of plastic)can be placed in contact with the resilient material of the guide. Them-frame assembly can then be slideably inserted into the seamlesshousing where the display device chassis rides along the resilientguide. The m-frame assembly is inserted until an active area of thedisplay device is centered with respect to a black mask within a displaywindow formed in the seamless housing. Once the display device iscentered, a protective cover glass having a locking feature such as aflange can be placed on the display and locked into place. The lockingin place of the protective cover can also have the effect of restrainingthe m-frame assembly in XY. Furthermore, the protective cover glass canalso assert a force onto the display device chassis that can be opposedby the resilient guides onto which the display device rests. Thisopposing force can have the effect of forcing the displaydevice/protective glass up against the housing thereby assuring that theprotective glass is substantially flush with the housing.

As described above, in order to properly align the various componentswithin the seamless housing after the display device is centered andfixed in place, the assembly operator is provided the opportunity tomove other components relative to the display device. However, in orderto facilitate this movement, the display device has what is referred toas a cross over flex that provides a modicum of additional length offlex used to accommodate the necessary movement of the other componentsrelative to the display device. Moreover, this cross over feature allowsfor greater allowance for the placement of a corresponding connector onthe PCB.

These and other embodiments of the invention are discussed below withreference to FIGS. 1-14. However, those skilled in the art will readilyappreciate that the detailed description given herein with respect tothese figures is for explanatory purposes as the invention extendsbeyond these limited embodiments.

FIG. 1A illustrates portable electronic device 1 in accordance with thedescribed embodiments. Device 1 can be configured as any of a number ofelectronic devices such as a portable media player, cell phone, smartphone, etc. In the described embodiment, portable electronic device 1can be modular in nature. By modular it is meant that device 1 can beformed of modules each containing a plurality of functional assemblies.This modularity can also facilitate efficient and cost effective modularassembly practices described below. In the described embodiments, themodules can be stand alone modules in that each module can be tested andconfirmed as being fully functional prior to being incorporated intodevice 1. In this way, only fully tested and fully operational modulescan be used in the assembly of device 1 thereby substantially improvingassembly yield. Modules, in turn, can include a plurality of functionalassemblies. The functional assemblies can include components arranged toperform specific functions. For example, a camera assembly can include acamera configured to provide both still and video to a processorassembly.

Device 1 can include frame 2 that can be used to provide mechanicalsupport for device module 3. Device module 3 can, in turn, include anumber of functional assemblies such as assembly 4 connected to assembly5 by way of interface 6. In the described embodiments, device module 3can be a stand alone module having a number of functional assembliesthat can be tested prior to assembly into the device 1. Being standalone, module 3 can be connected to an external circuit such as a testerconfigured for functional testing. Typically, the tester has an on boardpower supply arranged to supply a pre-determined supply voltage to thecircuit under test (i.e., module 3). As a result of the testing, anyassemblies found to be either malfunctioning or not operating accordingto spec can either be repaired or replaced. In this way, an inventory ofpre-tested device modules can be stored and made ready for assembly ofelectronic device 1.

Device 1 can be assembled in a labor and cost effective manner by takingadvantage of the modularity inherent in the design of device 1. Frame 2can be used as a transport mechanism (along the lines of a sled used totransport objects laid thereon) as well as a supporting structure. Sincemodule 3 is mounted to frame 2, frame 2 can be used to transport module3 into housing 7 in one operation avoiding the cost in time and labor ofin situ component assembly. Since module 3 has been fully tested andconfirmed operational prior to assembly, there is a high probability ofcontinued operability after the insertion procedure. However, even inthose rare instances where an inserted module is found to be defective,the defective module can be easily swapped for another functioningmodule. In this way, there is no need for time consuming failureanalysis. Device 1 also includes a separate user interface module 8that, like device module 3, can be fully function tested prior to beingelectrically coupled to device module 3 and incorporated into device 1.

The described embodiment can provide a number of features thatfacilitate the assembly of device 1. For example, assembly 4 and/orassembly 5 can be mobile with respect to housing 7 and/or each other. Insome cases it may be necessary to affix assembly 4 to a specificposition relative to an external reference (such as an opening inhousing 7, for example). One such example can be if assembly 4 includesa display device, the display device must be precisely centered withinan opening in housing 7. Therefore, once the display is centered, theposition of assembly 4 is fixed and cannot move relative to housing 7.However, even though assembly 4 must remain fixed, assembly 5 may haveto be aligned with respect to housing 7 at a position inconsistent withthe current relative position of assembly 4. Therefore, frame 2 caninclude an intra-frame transport mechanism on which assembly 5 can bemounted. The intra-frame transport mechanism can allow assembly 5 tomove relative to assembly 4. In order to accommodate any movementbetween assembly 4 and assembly 5, interface 6 can be expand (orcontract) commensurate with the relative displacement between assembly 5and assembly 4.

FIG. 1B illustrates a specific embodiment of modular portable electronicdevice 1 shown in FIG. 1A. More specifically, FIG. 1B shows a front andrear view of fully assembled handheld portable electronic device 10.Portable electronic device 10 can process data and more particularlymedia data such as audio, video, images, etc. By way of example,portable electronic device 10 can generally correspond to a musicplayer, game player, video player, camera, cell phone, personal digitalassistant (PDA), and/or the like. With regards to being handheld,portable electronic device 10 can be operated solely by the user'shand(s), i.e., no reference surface such as a desktop is needed. In somecases, portable electronic device 10 can be sized for placement into apocket of the user. By being pocket sized, the user does not have todirectly carry the device and therefore the device can be taken almostanywhere the user travels (e.g., the user is not limited by carrying alarge, bulky and heavy device). By way of example, the portableelectronic device 10 can correspond to consumer electronic products suchas computers, media players, personal digital assistants (PDA),telecommunication devices (phone), personal e-mail or messaging devicesand/or the like. In one example, the electronic device can correspond toan iPod Nano™ available by Apple Inc. of Cupertino, Calif.

Portable electronic device 10 can include housing 100 configured to atleast partially enclose any suitable number of components associatedwith the electronic portable electronic device 10. For example, housing100 can enclose and support internally various electrical components(including integrated circuit chips and other circuitry) to providecomputing operations for the device. The integrated circuit chips andother circuitry can include a microprocessor, memory, a battery, acircuit board, I/O, various input/output (I/O) support circuitry and thelike. Although not shown in this figure, housing 100 can define acavity, or lumen, into which various mounted components can be inserted.In the described embodiment, at least one fully tested stand aloneassembly having various operational components mounted thereon can beinserted into an open end of housing 100. Once properly positioned andfixed in place, a stand alone and fully tested user interface can beelectrically connected to the stand alone assembly and placed within auser interface opening in housing 100. The user interface can then belocked in place using one of two endplates that are placed on both ofthe open ends of housing 100. In this way, the endplates serve to sealthe operating components inside housing 100 preventing dust and otherenvironmental contaminants from entering. Cosmetic caps can be placedover the endplates to improve the overall aesthetics of portableelectronic device 10.

In addition to providing support and prevention of environmentalcontamination from damaging the internal components, housing 100 candefine at least in part the outward appearance of portable electronicdevice 10. That is, the shape and form of the housing 100 can helpdefine the overall shape and form of the portable electronic device 10or the contour of the housing 100 can embody the outward physicalappearance of the portable electronic device 10. Any suitable shape canbe used. In some embodiments, the size and shape of the housing 100 canbe dimensioned to fit comfortably within a user's hand. In someembodiments, the shape includes a slightly curved back surface andhighly curved side surfaces. The shape will be described in greaterdetail below. Housing 100 can be integrally formed in such as way as toconstitute is a single complete unit. By being integrally formed, thehousing 100 has a seamless appearance unlike conventional housings thatinclude two parts that are fastened together thereby forming a reveal, aseam there between. That is, unlike conventional housings, the housing100 does not include any breaks thereby making it stronger and moreaesthetically pleasing.

As seen on the front view, portable electronic device 10 can includedisplay 104. Display 104 can be fixedly mounted onto a supporting metalframe using a fixing agent such as adhesive that can also act as a dustshield. Display 104 can be used to display images such as video, stillimages, a graphical user interface (GUI) as well as other information tothe user (e.g., text, objects, graphics). By way of example, display 104can be a liquid crystal display (LCD). When portable electronic device10 is being assembled, the frame on which display 104 is mounted can beinserted into housing 100 using one of the open ends of housing 100until display 104 is centered within display window opening 106.Protective layer 108 can be positioned within opening 106 in front ofthe display 104 in order to protect display 104 from damage. Protectivelayer 108 can be formed from any of a number of clear materials such asclear polycarbonate plastic, glass, etc. In the described embodiment,protective layer 108 can include a locking feature (such as a flange).When protective layer 108 is placed over display 104 within the displaywindow opening 106, the locking feature can be mated with housing 100thereby applying pressure to display 104. The applied pressure has theeffect of locking into position the various internal components (such asa main logic board, or MLB) mounted to the supporting metal frame onwhich display 104 is also mounted.

Portable electronic device 10 can also include one or more input devicesconfigured to facilitate a transfer of data from the outside world intothe portable electronic device 10 and vice versa typically at the behestof a user. The one or more input devices can be used to performtracking/scrolling or to make selections or to facilitate a user issuingcommands to portable electronic device 10. By way of example, the one ormore input devices can correspond to keypads, joysticks, touch screens,touch pads, track balls, wheels, buttons, switches, and/or the like. Inthe described embodiment, the one or more input devices can include atouch sensitive input device that can take the form of click wheel userinterface 110 (being the visible portion of click wheel assemblydescribed in detail below). Click wheel user interface 110 can includeat least an annular click wheel 112. Annular click wheel 112 can beformed of resilient material such as plastic on which are present anumber of icons 114 each corresponding to a particular button functionthat can be performed by portable electronic device 10 in response to auser touch event. By way of example, where portable electronic device 10is a music player, the button functions can be associated with opening amenu, playing a song, fast forwarding a song, seeking through a menu andthe like. In most cases, the button functions are implemented via amechanical clicking action although they can also be associated withtouch sensing.

In order to convert the user touch event to a signal that can beprocessed and acted upon by portable electronic device 10, each icon 114can be associated with a corresponding touch sensitive region in theform of click wheel button 116. In order to reduce Z height of clickwheel user interface 110 and help to make it flush with the surface ofhousing 100, click wheel button 116 can take the form of a reversedorientation clickable dome button (also referred to as a reverse domebutton). By reverse orientation it is meant that the dome portion ofclick wheel button 116 is oriented to face down towards the interior ofportable electronic device 10 as opposed to facing up away from housing100 in conventional arrangements. Although not shown, each click wheelbutton 116 is associated with a sensor arrangement. The sensorarrangement can include a plurality of sensors that are configured toactivate as the finger passes over or presses on them. In the simplestcase, an electrical signal is produced each time the finger passes orpresses a sensor. The number of signals in a given time frame canindicate location, direction, speed and acceleration of the finger onthe touch pad, i.e., the more signals, the more the user moved his orher finger. In most cases, the signals are monitored by an electronicinterface that converts the number, combination and frequency of thesignals into location, direction, speed and acceleration information.This information can then be used by portable electronic device 10 toperform the desired control function.

Click wheel user interface 110 can also include center button 118associated with touch sensitive region 120. When a user presses centerbutton 118, for example, touch sensitive region 120 can generate asignal that can cause portable electronic device 10 to act in apre-determined manner. For example, when a user presses center button118 at the same time that a list of media items are presented on display104, touch sensitive region 120 can provide a signal to processingcircuitry that can cause a particular one of the listed media itemspresented on display 104 to be selected. It should be noted that centerbutton 118 can also be configured as a reverse dome button.

The position of click wheel user interface 110 relative to seamlesshousing 100 can be widely varied. For example, click wheel userinterface 110 can be placed at any external surface (e.g., top, side,front, or back) of seamless housing 100 that is accessible to a userduring manipulation of the portable electronic device 10. Typically,touch sensitive surfaces of click wheel user interface 110 arecompletely accessible to the user. For example, click wheel userinterface 110 can be located in a lower, front area of seamless housing100. Furthermore, click wheel user interface 110 can be recessed below,level with, or extend above the surface of the seamless housing 100. Inthe illustrated embodiment, however, the touch sensitive surfaces ofclick wheel user interface 110 are substantially flush with the externalsurface of the seamless housing 100.

The shape of click wheel user interface 110 can also be widely varied.For example, click wheel user interface 110 can be circular,rectangular, square, oval, triangular, and the like. Circular shapes,however, allow a user to continuously swirl a finger in a free manner,i.e., the finger can be rotated through 360 degrees of rotation withoutstopping. Furthermore, the user can rotate his or her fingertangentially from all sides thus giving it more range of fingerpositions. For example, when the portable electronic device 10 is beingheld, a left handed user can choose to use one portion of click wheeluser interface 110 while a right handed user can choose to use anotherportion of click wheel user interface 110.

Portable electronic device 10 can also include one or more switches suchas power switches, hold switches, and the like accessible throughvarious openings in housing 100. The power switch is configured to turnthe portable electronic device 10 on and off, and hold switch 122 isconfigured to activate or deactivate click wheel user interface 110.This is generally done to prevent unwanted commands by click wheel userinterface 110, as for example, when portable electronic device 10 isstored inside a user's pocket.

Portable electronic device 10 can also include one or more connectorsfor transferring data and/or power to and from portable electronicdevice 10. Portable electronic device 10 can include audio jack 124,data port 126 and in some cases a separate power port for deliveringpower to the portable electronic device 10. Audio jack 124 allows audioinformation to be outputted from portable electronic device 10. Audiojack 124 can receive an audio post (not shown) that can provide audiosignals to external audio rendering devices, such as headphones,speakers, etc. Data port 126 allows data to be transmitted and receivedto and from a host device such as a general purpose computer (e.g.,desktop computer, portable computer). For example, data port 126 can beused to upload or down load audio, video and other image data to andfrom the portable electronic device 10. Data port 126 can also be usedto download songs and play lists, audio books, e-books, photos, and thelike into a storage mechanism included in portable electronic device 10.In the described embodiment, data port 126 can be any size deemedappropriate such as, for example, a 30 pin connector. As seen by therear view, portable electronic device 10 can also include a cameramodule having camera lens 130, the camera module being configured toprovide still or video images. Cosmetic camera trim 132 can provide anaesthetically pleasing finish as well as provide support for camera lens130. A microphone can be used to record audible sound passing throughmicrophone hole 134. In the described embodiment, cosmetic trim 132 canform fit into trim recess 136 formed from housing 100. Trim recessportion 136 of housing 100 can be formed using a machining process, forexample. Although not shown in FIG. 1B but described in detail later,trim recess portion 136 can include openings in housing 100 used toprovide access to the microphone module, the camera module and anopening used to insert a camera alignment pin. It should be noted thatcosmetic trim 132 can obscure the opening used to insert the cameraalignment pin since such an opening only need be accessed during thealignment of the camera module.

In some cases, the data port 126 can serve as both a data and power portthus replacing the power port. Data port 126 can be widely varied. Inone embodiment, the data port 126 is a peripheral bus connector, such asa USB or FIREWIRE connector. These type of connectors include both powerand data functionality, thereby allowing both power delivery and datacommunications to occur between the portable electronic device 10 andthe host device when the portable electronic device 10 is connected tothe host device. In some cases, the host device can provide power to themedia portable electronic device 10 that can be used to operate theportable electronic device 10 and/or charge a battery included thereinconcurrently with the operating.

Although the device can connect through various wired connections, itshould be appreciated that this is not a limitation. Portable electronicdevice 10 can also include a mechanism for wireless communications, aseither a transceiver type device or receiver only, such as a radio. Forexample, as shown, portable electronic device 10 can include an antennathat can be disposed internal to housing 100. The wirelesscommunications can be based on many different wireless protocolsincluding for example Bluetooth, RF, 802.11, FM, AM, and the like.

FIG. 2 shows an exploded view 200 of portable electronic device 10illustrating the juxtaposition of various electrical and structuralcomponents described in more detail below. The relationship andorganization of the components within each layer and relationshipbetween layers can be used to facilitate both the assembly andoptimization of Z height tolerances of portable electronic device 10.One aspect of the described embodiments relates to the design of theoperational components that facilitate modular assembly of portableelectronic device 10. The modular assembly relates to the fact thatportable electronic device 10 is formed of a number of self containedmodules. These self contained modules can be powered up and tested andif necessary repaired or tuned prior to being inserted into housing 100.In this way portable electronic device 10 can be manufactured to beextremely compact, sturdy, aesthetically pleasing and ergonomic atrelatively low cost. The pre-assembled and pre-tested modules caninclude click wheel assembly 400 and metal or m-frame assembly 500described in more detail below.

FIG. 3 is a detailed front and rear view of housing 100. Housing 100 cantake the form of a seamless housing. The seamless nature of the housing100 provides an aesthetic look and feel to the portable electronicdevice 10 as well as provides added resistance to deformation andpossible damage to internal components caused by the device beingdropped. Housing 100 can be formed of extruded aluminum or othermaterials such as plastic. It should be noted, however, that thisconfiguration is representative in nature only and does not providelimitations constraining the ultimate scope of the invention. The sizeand shape of seamless housing 100 can be dimensioned to fit comfortablywithin a user's hand. In one particular embodiment, seamless housing 100can be formed from an extruded material such as aluminum or stainlesssteel thereby providing a seamless look along the length of portableelectronic device 10. That is, unlike conventional seamless housings,seamless housing 100 does not include any breaks between the top andbottom ends thereby making it stronger and more aesthetically pleasing.It should be noted that in those cases where portable electronic device10 incorporates radio frequency (RF) functionality, such as WiFi,BlueTooth, AM/FM radio, any metals used for construction of seamlesshousing 100 should possess non-magnetic properties in order to reduceany possibility of interfering with the RF functionalities. Such metalscan include, for example, aluminum.

In order to help guide at least a portion of the internal components totheir desired position within the seamless housing 100 during assembly,housing 100 can include display opening 302 arranged to accommodatedisplay 104 and cover glass 108. During assembly, an operator can centerdisplay 104 to display opening 302. Housing 100 can also include clickwheel assembly opening 304 arranged to receive fully functional clickwheel assembly. Flanges 305 can be used to lock the click wheel assemblyin the Z direction. Lumen 306 can be sized and dimensioned for receiptof various internal components used in the assembly of portableelectronic device 10. In the described embodiment, an internal referencestructure within lumen 306 can include at least two groove structures308 formed in inner surface 310 of back portion 312 of seamless housing100. Grooves 308 can be formed by way of a machining process. Oncegrooves 308 have been formed, similarly shaped rails formed of plasticor other resilient material can be fitted into grooves 308 and attachedto inner surface 310. In this way, the rails can provide both anassembly reference surface and a supporting structure for pre-assembledcomponents such as a plastic chassis on which display 104 is mounted.

Cover glass 108 can be locked into place (i.e., in the XY plane) bybonding cover glass 108 to metal frame using adhesive. Cover glass 108can be locked into the Z direction using flanges formed on cover glassframe which can then be snapped into housing 100. Once cover glass 108is locked into place, the compressive force applied by cover glass 108onto the metal frame can be transmitted through the metal frame down tothe resilient material in grooves 108 upon which the metal frame rests.The resilient material can respond to the compressive force with anopposing force that travels up through the metal frame to cover glass108. This opposing force can have the effect of biasing up the metalframe and cover glass 108 (on which cover glass 108 is mounted) therebyforcing cover glass 108 up against housing 100. In this way, the uppersurface of cover glass 108 can be made flush with the upper surface ofhousing 100 at display opening 302.

In order to maximize the perceived audio output of an integrated speakerassembly used by portable electronic device 10 to broadcast audiblesound, a portion of inner surface 310 can be removed to form recess 314.Recess 314 can be used to form a front acoustic volume associated with apiezo-electric acoustic transducer. It should be noted that as describedbelow, during assembly, a front acoustic volume can be created byforming a sliding seal between an acoustic seal associated with apiezo-electric audio transducer and recess 314.

In order to more easily accommodate the insertion of various internalcomponents within seamless housing 100, open end 316 (opposite open end318) can receive a self contained unit formed of operational componentsmounted to a metal frame, or sled. At the conclusion of the assemblyprocess, an end cap having a click wheel locking feature can be used tocover open end 316 and lock click wheel user assembly in place in the XYdirection. The end caps are shaped to conform to the internal crosssection of housing 100. In this way, end caps can be inserted into theopen ends 316 and 318 such that an outer periphery of the end capsmatches an inner periphery of lumen 306. Furthermore, cosmetic caps canbe subsequently placed on the end caps and positioned to be flush withrear surface and front surface of seamless housing 100 thereby providingseamless housing 100 with a substantially uniform appearance.

FIG. 4 shows various views of click wheel assembly 400. The viewsinclude an exploded view and a reverse view of click wheel flex showingreverse dome buttons in accordance with the described embodiments. Itshould be noted that by self contained it is meant that once fullyassembled, click wheel assembly 400 is fully functional and capable ofbeing function tested prior to incorporation into portable electronicdevice 10. In this way, click wheel assembly 400 can be tested and, ifnecessary, repaired or tuned, prior to incorporation into portableelectronic device 10. Turning first to the exploded view, click wheelassembly 400 can include a number of structural and electricalcomponents that cooperate to provide a user input device responsive to atouch event be it from a user's finger, or a stylus, etc. In thedescribed embodiment, the click wheel assembly 400 can include annularlyshaped click wheel faceplate 402 and center button plate 404 sized tofit within a central portion of click wheel faceplate 402. Center buttonplate 404 can be metallic in nature (for both aesthetic and wearprotection reasons) whereas click wheel faceplate 402 can be formed ofplastic or other lightweight yet durable material. The choice of metalfor center button plate 404 and plastic or plastic like material forclick wheel faceplate 402 is based upon the fact that it is contemplatedthat center button plate 404 will receive substantially greater wearfrom repeated user touches and presses than will click wheel faceplate402. Any disadvantages due to the metallic nature of center button plate404 (greater weight, higher cost of fabrication, etc.) is more thanoffset by the anticipated longer useful lifetime of center button plate404 than would be expected if center button plate 404 had beenfabricated with plastic or other such material. In any case, the natureof the material used to form the various buttons can be varied dependingon any number of factors in addition to those discussed above.

Click wheel faceplate 402 can provide a surface that can cooperate witha number of reverse mounted click wheel dome buttons 406 electricallyconnected to click wheel flex 408. The number of placement of domebuttons 406 can be widely varied. In the particular embodiment shown,dome buttons 406 form an array of four buttons circumferentiallyarranged equidistant from each other on click wheel flex 408. Clickwheel flex 408 can be disposed between click wheel faceplate 402 andclick wheel support plate 410. Center button plate 404 can provide asurface that can cooperate with reverse mounted center dome button 412that is mounted to center button flex 414 by way of “ears” 415 andelectrically connected to click wheel flex 408 by way of single flexconnector 416. Center button plate 404 can also be directly mounted tocenter button flex 414. One advantage to using single flex connector 416and ears 415 is to help reduce the overall height (Z) of click wheelassembly 400. It should be noted that click wheel dome buttons 406 andcenter dome button 412 can be located on the same side of click wheelflex 408 and center button flex 414, respectively, thereby requiringonly a single set up to manufacture. In addition, using only flexconnector 416 and to connect center button flex 414 and click wheel flex408, less material can be used in the manufacture of click wheelassembly 400. Moreover, the single connection provides for easierplacement and rotational alignment of click wheel assembly 400 intohousing 100.

Click wheel support plate 410 is used to provide structural support forclick wheel assembly 400. Accordingly, click wheel support plate 410 canbe formed from a number of metal plates formed of, for example,stainless steel (such as SUS 304L) that are fusion bonded together attemperatures in the range of 1000° F. The metal plates can be ofdifferent thickness. Fusion bonding results in click wheel support plate410 having a laminated structure that has both strength and a highdegree of Z conformity (i.e., very flat). It is this combination ofstrength and flatness that enables click wheel assembly 400 to present amore uniform touch sensitivity profile across click wheel faceplate 402and center button plate 404 to the user. It should be noted that priorto the fusion bonding, some of the constituent plates can be chemicallyetched to form, for example, dome button recesses 416 suitable forreceiving dome button shims 418.

In order to assemble click wheel assembly 400, click wheel faceplate402, center button plate 404, and click wheel flex 408 are attached toclick wheel support plate 410 (after the placement of shims 418) usingfasteners 420. Once assembled, adhesive 422 can be used to bond clickwheel support plate 410 to a supporting structure (such as a printedcircuit board, or PCB) already inserted and fixed within housing 100. Inorder to prevent diving (movement by click wheel assembly 400 in the Zdirection when a user applies pressure), click wheel support structure424 can be used to provide additional support to click wheel assembly400. Click wheel support structure 424 can be formed of plastic or otherrelated material. Prior to click wheel support plate 410 being placedand fixed within housing 100 and connected to main logic board usingelectrical connector 428, click wheel support structure 424 can bedropped, or otherwise placed, within an accommodating space in thesupporting structure (such as PCB) upon which click wheel support plate410 is subsequently bonded. In the described embodiment, click wheelsupport structure 424 can include a central bore arranged to accommodatemetallic spring 426. Metallic spring 426 can be placed in physicalcontact with (metallic) click wheel support plate 410 and (metallic)housing 100. In this way, metallic spring 426 can be used to bothprovide resilient support for click wheel assembly 400 and a conductivepath to ground (i.e., between click wheel support plate 410 and housing100).

FIG. 5 shows a front and rear view of m-frame assembly 500 in accordancewith the described embodiments. M-frame assembly 500 can include someoperational components mounted to metal frame 502 whereas the remainingoperational components can be mounted to main logic board, or PCB 504,that in turn can be mounted to metal frame 502. Some components, such asdisplay device 104, are mounted to metal frame 502 at a fixed position,whereas other components can be mounted to metal frame 502 and yet bemoved along the Y axis relative to display device 104. Componentsmounted to metal frame 502 can be electrically connected to PCB 504 byway of connectors, or flex. Such connectors can include I/O flex 506.I/O flex 506 can connect microphone module 518, hold button circuit 510,audio module 512, and piezo-electric audio transducer (or more simply,piezo) 520 to PCB 504 using a single board to board (B2B) connector (notshown). Cross over flex 514 (shown in a folded state) can be used toconnect display 104 and associated circuitry on PCB 504. Microprocessor516 and data port 522 can be connected directly to PCB 504. In thedescribed embodiment, data port 522 can be configured as a 30 pinconnector. It should also be noted that in order to securely mate withan external data bus, data port 522 can include latching/alignment holes523 on either or both sides of data port 522. In order to prevent dustor other contamination from entering portable electronic device 10 atthe latching holes 523 (with the possibility of obscuring camera lens132) cosmetically appealing dust seals can be placed over latching holes523. By cosmetically appealing it can be meant that the resilientmaterial (such as silicone) can be black or other dark color that cannotbe readily seen within connector 522 from an outside observer.

Battery 524 which can be located at the rear of display device 104.Battery 524 can operatively coupled to PCB 504 and its variouscomponents using a solder connector that couples battery 524 to aconnector located on PCB 504. Battery 524 can correspond to arechargeable lithium polymer battery or a lithium ion prismatic cell. Itshould be noted that once battery 524 is connected to PCB 504, m-frameassembly 500 can be functionally tested and if necessary, repaired,tuned, or otherwise modified prior to being inserted into housing 100during the final assembly operation. Acoustic seal 526 can be used toform a front acoustic volume in conjunction with space 314 when m-frameassembly is slid into housing 100 forming a sliding seal betweenacoustic seal 516 and recess 314 to form a front acoustic volume.

FIG. 6 shows an embodiment of metal frame 502. Metal frame 502 canprovide a metallic support structure upon which a plurality ofsub-assemblies formed of associated operational components can bemounted to form metal (m) frame assembly 500. Metal frame 502 can be amultipart metal frame formed of at least two frame components formed ofmetal (such as stainless steel) that can be laser welded together. Forexample, metal frame 502 can be formed of display support portion 602and main logic board (or printed circuit board, PCB) support portion 604laser welded together. Metal frame 502 can also include a number ofintegrated features. These integrated features can improve operation ofportable electronic device 10 (by providing a robust path to chassisground) as well as being extremely useful in the assembly of bothm-frame assembly 500 as well as the final assembly of portableelectronic device 10.

A plurality of ground tabs can be formed into metal frame 502 at variouslocations that can be used to provide a conductive path to chassisground (housing 100). For example, front ground tab 606 can be used toprovide a conductive path from click wheel assembly 400 to a front,lower portion of housing 100 whereas ground tabs 608 can be used toprovide a conductive path to the rear portion of housing 100 whereasground tabs 610 can provide good grounding for processor 516 and othercomponents mounted to PCB 504.

Another useful feature relates to a system for using rail-likestructures to provide limited movement along the Y axis of componentsattached to metal frame 502. In the described embodiment, rail system612 can be formed by folding corresponding portions of frame 502approximately 90 degrees (forming “U” channels in the process).Components mounted to rail system 612 can then be moved along the Y axiswith respect to those components fixedly mounted to metal frame 502,such as display 104. This relative movement between components can beimportant since certain components, such as display 104 and audio jack124, must be precisely set within housing 100 for both functional andaesthetic reasons. For example, when m-frame assembly 502 is insertedinto housing 100, display 104 is fixed to metal frame 502 at displaymounts 614. (It should be noted that using the orientation shown in FIG.6, display 104 is mounted to metal frame 502 at display mounts 614 fromthe bottom up such that display 104 is facing up as indicated.) As shownbelow, display 104 can be mounted to metal frame 502 at an LCD sealusing adhesive (that acts as a bonding agent as well as dust shield).During assembly, metal frame 502 on which display 104 is bonded isslidably inserted into housing 100 until display 104 is centered withinwindow 108. Since it is crucial that display 104 remain centered, anymovement of display 104 after being centered is not acceptable. However,since audio jack 124 and connector 126 must be set flush to the bottomof housing 100, PCB 502 (along with data connector 126 and audio jack124) must be able to move along the Y axis while display 104 remainsstationary in order to easily align data connector 124 and audio jack124.

The architecture of metal frame 502 can facilitate the mounting ofcomponents onto metal frame 502 using what can be referred to as “book”type assembly techniques. Book type assembly techniques refers toinstalling components (such as PCB) on metal frame 502 by using anundercut feature on one side of metal frame 502 to place a component anda snap attaching feature on the other side of metal frame 502 to receiveand snap in place the component. Accordingly, metal frame 502 includesan undercut feature 616 (side A) and a snapping feature 618 (side B). Anassembly operator using the book assembly technique would use undercutfeature 616 on side A to place a component (such as PCB 504) onto metalframe 502 and then, as one would close a book, lower the other side ofPCB 504 to be snapped into place by snapping feature 618 at side B ofmetal frame 502. Rail system 612 can then provide for moving theattached component in either direction along the Y axis. In this way,book type assembly limits the number of fasteners required and allowsfor substantially easier assembly.

In order to facilitate the transport of the acoustic energy provided bypiezo-electric transducer 520, a plurality of porting holes 620 can bepunched into support plate 622. In this way, an acoustic back volume canbe created in part (using various leak paths to other interior portionsof portable electronic device 10 as the remaining back volume) that incombination with an acoustic front volume (formed in conjunction withacoustic seal 524 and recess 314) can together provide a substantiallyimproved use audio experience.

FIG. 7 shows an embodiment of display device 700 having cross over flex702 in a folded state and an extended, or open, state. Display device700 can include display 104 that can take the form of a liquid crystaldisplay (LCD) 104 that can be bonded onto metal frame 502 at displaymounts 616 using, for example, adhesive or other appropriate bondingagent. Display device 700 can be operatively connected to PCB 504 andits various components by way of cross over flex 702 at connector 704.As shown, cross over flex 702 can be of sufficient length to be foldedover to form a service loop. This service loop enables an assemblyoperator to move PCB 504 along the Y axis using rails 612 in order tomore precisely align various components (such as audio jack) to openingsin housing 100. Furthermore, the cross over feature provides for greatlyvarying the location of the location where connector 704 can be used onPCD 504.

FIG. 8A shows an embodiment of microphone/camera assembly 800. Cameraassembly 800 can include camera module 508, camera boot 802 andmicrophone 812. Camera module 508 can include camera body 804 havingcamera opening 806. Camera body 804 can be connected to PCB 504 by wayof camera flex 808 and connector 810 but is free floating since it mustbe mounted, aligned and then sealed without moving PCB 504. Cameraalignment pin 814 (shown in FIG. 8B) can be used to fix camera module508 into place using alignment hole 807 in camera arm 809. Cameraalignment pin 814 can be fix camera module 508 in place by beinginserted into camera alignment pin hole 140 in housing 100, pass throughalignment hole 807 in camera arm 809 to rest in camera alignment pinrecess 811. In this embodiment shown in FIG. 8B, camera alignment pinrecess 811 can be machined from an inner surface of the front of housing100. It should be noted that recess 136 formed on the back of housing100 can include camera opening 138, camera alignment pin opening 140,and microphone opening 142. In the described embodiment, cameraalignment pin opening 140 is covered by camera trim 132. In this way,only microphone opening 142 and camera opening 138 (having camera lens130 included therein) can be seen by a user.

In the described embodiment, camera flex 808 is “S” shaped. Being “S”shaped allows an assembly operator to move camera 804 in relation to PCB504 in order to maintain the alignment of camera lens 130 and camerahole 806. Camera boot 802 can be formed of silicone or other relatedmaterial and can enclose camera module 508 providing protection againstimpact as well as environmental contaminants such as water, dust, etc.As shown in FIG. 8C in side view, camera boot 802 can include a numberof camera boot grooves 820 that can be used to form dust seal as aresult of camera module 508 being slideably inserted into housing 100.This is particularly important due to the elevated probability ofcontamination from dust or other contaminants from the outsideenvironment due to the proximity to camera 804 of the latching holes 523present in port 522.

FIG. 9 shows an embodiment of I/O flex 506. I/O flex 506 can connectaudio module 512, microphone module 518, hold button circuit 510 (by wayof hold switch circuit connector 902), and piezo-electric audiotransducer 520 to an external circuit (such as PCB 504 or a separatepower supply) by way of board to board connector 904. As shown, I/O flex506 can include service loop portion 906 connecting body 908 of I/O flex506 to hold button circuit connector 902. Service loop portion 906 canprovide the assembly operator the ability to adjust the position of holdswitch 122. An advantage to I/O flex 506 lies in the fact that once aparticular component(s) (audio module 512, for example) is/are connectedto I/O flex 506, connector 904 can be connected to an external powersupply either directly or by way of another circuit or circuit board(such as a test fixture) for stand-alone testing of any or all of thecomponents connected thereto.

FIG. 10 shows a top and bottom view of audio module 512 in accordancewith the described embodiments. Audio module 512 can be operativelycoupled to the PCB 504 and its various components by way of I/O flex506. Audio module 512 can include an audio processing circuit 1002 andan audio jack 124. Audio module 512 can be accommodated by audio modulecut-out of metal frame 502 and mechanically coupled to the PCB 504 byway metal frame 502 so that the PCB 504 and audio module 512 can form anintegrated structure. By way of example, they can be both be coupled tometal frame 502 together using fasteners, and/or snaps. Stiffener plate1004 (seen in the bottom view of audio module 512) can be used to attachI/O flex 506 to audio module 512. Stiffener plate 1004 can be formed ofmetal such as stainless steel (tin plated for example), gold, etc.Stiffener plate 1004 can also include stiffener arm 1006 used to preventundue flexion in flex 506 by distributing stress more evenly acrossstiffener plate 1004. Stiffener plate 1004 can also include a locatorhole (not shown) arranged to accommodate locator post 1008 on PCB 504.During the assembly of audio module 512 on PCB 504, the locator hole canbe mated to locator post 1008 in order to more easily align audio module512. Furthermore, by soldering locator post 1008 to stiffener plate1004, a suitable RF ground can be obtained providing for an FM antennaand associated circuitry to be ported through audio module 512. Itshould be noted that metal hold down screw 1010 can securely fasten I/Oflex 506 to audio module 512. Metal hold down screw 1010 can provideadditional grounding.

FIG. 11 shows a representation of cover glass assembly 1100 inaccordance with the described embodiments. Display device 700 caninclude plastic chassis (p-chassis) 1102 providing support forcomponents used to form display device 1100. Such components can includedisplay circuits layer 1104 (in the form of TFT or twisted fieldtransistors) mounted between TFT glass layer 1106 and color filter glasslayer 1108. In the described embodiment, bottom polarizer layer 1110 canbe attached to a bottom surface of TFT glass layer 1106 and a toppolarizer layer 1112 can be mounted to an upper surface of color filterglass layer 1108. LCD seal layer has a lower surface attached to uppersurface of top polarizer layer 1112 and an upper surface bonded to metalframe 502 at display mounts 614. In this way, in contrast toconventional approaches, p-chassis 1102 is not bonded directly to metalframe 502. Black mask 1114 can be placed under cover glass 108. Blackmask 1114 can be used to define the viewable, or active area, of display104. Cover glass seal 1116 can be used to seal the area between blackmask 1114 and metal frame 502.

FIGS. 12-14 are flowcharts describing method 1200 of manufacturing aportable electronic device in accordance with the described embodiments.The method generally includes several operations including: theformation of the seamless housing, the insertion of fixing of m-frameassembly into the seamless housing, and the placement and fixing ofstand-alone click wheel assembly into the seamless housing, and theplacement end caps and cosmetic caps sealing the seamless housing.

Referring first to FIG. 12 and the formation of the seamless housing,the operation starts with block 1202 where a tube is extruded. Followingblock 1202, the operation proceeds to block 1204 where the extruded tubeis cut to a desired length thereby exposing open ends. Following block1204, the operation proceeds to block 1206 where the access openings areformed in the extruded tube. By way of example, the access openings canbe associated with a user interface of the electronic device, a displaywindow, and a camera opening. Following block 1206, the operationproceeds to block 1208 where at least two grooves are formed into abottom inside surface of the extruded tube. By way of example, thegrooves can be formed by machining the bottom inside surface of theextruded tube. Following block 1208, the operation proceeds to block1210 where an acoustic pocket is formed on the bottom inside surface ofthe extruded tube. The acoustic pocket can be formed by machining aspecific amount of the extruded tube. Following block 1210, resilientmaterial, such as plastic is attached to the grooves at 1212.

Referring now to FIG. 13, during assembly and referring to the open endof the seamless housing, m-frame assembly can be inserted into the lumenof the seamless housing as a single unit at 1214. Metal frameessentially acts as a carrier for placing these components inside theseamless housing. During assembly, m-frame assembly can be inserted intolumen by sliding m-frame assembly through open end until display iscentered within housing at 1216. Once display is centered, cover glasscan be placed on top of display at 1218. Cover glass can then be seatedto the display using adhesive and locked to housing by way of a flangeon cover glass at 1220. The force of pushing cover glass onto display isresisted by the resilient material attached to grooves causing displayto be biased up in such as way as to affix display device to metalframe.

Turning now to FIG. 14, once display has been centered within window andfixed in place, cross over flex can allow PCB to be moved as necessaryto align audio jack, camera, and piezo at 1222. Once m-frame assemblyand its constituent parts have been aligned to the appropriate positionsvis a vis housing, click wheel assembly support can be dropped orotherwise placed into an appropriate space in PCB at 1224. Once clickwheel support is in place, click wheel assembly can be electricallyconnected to PCB at 1226 and then placed within the seamless housing inthe click wheel opening at 1228. Click wheel assembly can be aligned tohousing and in particular, center button can be rotatably aligned asneeded to conform to the shape of housing at 1230. End caps can then beused to seal portable electronic device and to lock click wheel assemblyin place at 1232. Cosmetic covers can be placed over end caps at 1234.

While this invention has been described in terms of several preferredembodiments, there are alterations, permutations, and equivalents, whichfall within the scope of this invention. It should also be noted thatthere are many alternative ways of implementing the methods andapparatuses of the present invention. For example, although an extrusionprocess is preferred method of manufacturing the integral tube, itshould be noted that this is not a limitation and that othermanufacturing methods can be used (e.g., injection molding). It istherefore intended that the following appended claims be interpreted asincluding all such alterations, permutations, and equivalents as fallwithin the true spirit and scope of the present invention.

What is claimed is:
 1. A portable electronic device, comprising: ahousing having walls that define an internal cavity and comprising afirst wall and a second wall opposite the first wall, the second wallhaving edges that define a display opening that extends through thesecond wall, the first wall having a resilient reference structureattached to an interior surface of the first wall opposite the displayopening and comprising a rail formed of resilient material differentfrom the housing and that extends out from the interior surface and intothe internal cavity; and an internal frame member that uses theresilient reference structure as a reference surface for insertion andplacement within the internal cavity and comprising: a display coverassembly comprising a display cover frame having flanges and a displaycover attached to the display cover frame, wherein the flanges engagethe second wall and lock the display cover within the display openingresulting in a compressive force being applied to the internal framemember that is transmitted to the resilient reference structure thatresponds by providing an opposing force that biases the display coveragainst the second wall.
 2. The portable electronic device as recited inclaim 1, wherein when the display cover is locked in place, an outersurface display cover is flush with an exterior surface of the secondwall.
 3. The portable electronic device as recited in claim 1, whereinthe single piece housing comprises a smoothly varying cross section, afirst opening at a first end, and a second opening at a second endopposite the first end.
 4. The portable electronic device as recited inclaim 3, wherein the flange is disengaged from the housing by aninwardly directed unlocking force applied at the exterior surface of thedisplay that exceeds the opposing force.
 5. The portable electronicdevice as recited in claim 4, wherein the internal frame assemblycomprises a number of operational components at least one of which is abattery.
 6. The portable electronic device as recited in claim 1,wherein the resilient reference structure further comprises a grooveformed by removing a corresponding amount of the second wall, whereinthe resilient material overfills the groove to extend out from theinterior surface and into the cavity.
 7. The portable electronic deviceas recited in claim 6, wherein the resilient reference structure is usedto guide the internal frame assembly into the single piece housing untilthe internal frame module is locked into place.
 8. The portableelectronic device as recited in claim 3, wherein the internal framemodule has a size and shape in accordance with at least one of the firstopening and the second opening.
 9. The portable electronic device asrecited in claim 1, wherein the single piece housing comprises a metal.10. An electronic device, comprising: a housing including a number ofwalls that cooperate to define an internal volume; a frame memberseparate and distinct from the housing that is disposed within theinternal volume and carries a number of electrical components, theelectrical components including a display assembly comprising a displayfor presenting visual content and a protective cover overlaying thedisplay, the display assembly secured to a side of the internal framemember that faces a first wall of the housing that comprises a displayopening that accommodates the protective cover; and a resilientreference structure attached to an interior surface of a second wallopposite the display opening and comprising a rail formed of resilientmaterial different from the housing and that extends out from theinterior surface and into the interior volume and that locks theprotective cover in place within the display opening by biasing theprotective cover against an interior surface of the first wall.
 11. Theelectronic device as recited in claim 10, further comprising: a printedcircuit board (PCB) secured to the frame member by a snap attachmentfeature of the frame member.
 12. The electronic device as recited inclaim 11, further comprising a user interface assembly support mountedto a surface of the PCB.
 13. The electronic device as recited in claim12, further comprising a user interface supported above the PCB by theuser interface support and disposed within an opening defined by thehousing.
 14. The electronic device as recited in claim 13, wherein theuser interface is a touch sensitive user interface electrically coupledto the PCB by way of the user interface support.
 15. The electronicdevice as recited in claim 10, wherein the housing comprises an extrudedmetal tube.
 16. A method of assembling a portable electronic device,comprising: the portable electronic device comprising: a housing havingwalls that define an internal cavity and a resilient reference structureattached to an interior surface of a wall opposite a display opening andcomprising resilient material different from the housing and thatextends out from the interior surface and into the internal cavity,using the resilient reference structure as a guide for inserting andplacement of an internal frame member within the internal cavity, theinternal frame member comprising: a display cover assembly comprising adisplay cover frame having flanges and a display cover attached to thedisplay cover frame; and engaging the flanges at the display opening,wherein the engaging causes a compressive force to be applied to theinternal frame member that is transmitted to the resilient referencestructure that responds by providing an opposing force that biases thedisplay cover against the display opening.
 17. The method as recited inclaim 16, further comprising: a printed circuit board (PCB) secured tothe internal frame member by a snap attachment feature of the internalframe member.
 18. The method as recited in claim 16, further comprisinga user interface assembly support mounted to a surface of the PCB. 19.The method as recited in claim 18, further comprising a user interfacesupported above the PCB by the user interface support and disposedwithin an opening defined by the housing.
 20. The method as recited inclaim 19, wherein the user interface is a touch sensitive user interfaceelectrically coupled to the PCB by way of the user interface support.